High texture replication rate sheet compositions, methods of manufacture, and articles made therefrom

Abstract

A replication composition includes at least 45 weight percent (wt) of a polycarbonate; 3 to 55 wt % of a polyester comprising a poly(C1-6 alkylene) terephthalate or a polyester comprising repeating units of Formula I: (I); wherein each T is independently a C5-7 cycloaliphatic group or C6-12aromatic group, and each D is independently a C6-12 aromatic group or C2-12 aliphatic group, provided that at least 50 mole percent of D is a 1,4-cyclohexanedimethyl group or a C2-12 aliphatic group; wherein the polyester has a melt viscosity between 0.01 and 3,000 poise (0.001 and 300 Pa·s) measured at 1500/seconds shear rate, at a temperature of 275° C.; and 0.01 to 4 wt % additives; wherein the weight percentages are based on 100 wt % of the composition.

1 . A replication composition, comprising:
 at least 45 wt %, of a polycarbonate;   3 to 55 wt %, of a polyester comprising a poly(C 1-6  alkylene) terephthalate or a polyester comprising repeating units of Formula 1:   
       
         
           
           
               
               
           
         
       
       wherein each T is independently a C 5-7  cycloaliphatic group or C 6-12  aromatic group, and each D is independently a C 6-12  aromatic group or C 2-12  aliphatic group, provided that at least 50 mole percent of D is a 1,4-cyclohexanedimethyl group or a C 2-12  aliphatic group; wherein the polyester has a melt viscosity between 0.01 and 3,000 poise (0.001 and 300 Pa·s), measured at 1500/seconds shear rate, at a temperature of 275° C.; and
 0.01 to 4 wt % additives; 
 wherein the weight percentages are based on 100 wt % of the composition. 
 
     
     
         2 . The composition of  claim 1 , wherein the polyester comprises a poly(C 1-6  alkylene) terephthalate, a poly(cyclohexane di(C 1-6  alkanol) cyclohexyl dicarboxylate), or a copolymer comprising a poly(C 1-6  alkylene)glycol terephthalate and a poly(cyclohexane di(C 1-6  alkylene) terephthalate). 
     
     
         3 . The composition of  claim 1 , wherein the additives are UV stabilizers, phosphorous stabilizers, heat stabilizers, antioxidants, hydrolytic stabilizers, mold release agents, extrusion aids, antistatic agents, quenchers, slip agents, coloring agents, lubricants, or a combination comprising at least one of the foregoing. 
     
     
         4 . The composition of  claim 1 , wherein the polycarbonate comprises repeating structural carbonate units of Formula (5): 
       
         
           
           
               
               
           
         
       
       where R a  and R b  are each independently a halogen atom or a monovalent hydrocarbon group with from 1 to 12 carbon atoms; p and q are each independently integers from 0 to 4; and each X a  is independently one of the groups: 
       
         
           
           
               
               
           
         
       
       wherein R c  and R d  are each independently a hydrogen atom or a monovalent linear hydrocarbon group with from 1 to 12 carbon atoms, or a cyclic hydrocarbon group with from 7 to 12 carbon atoms, and R e  is a divalent hydrocarbon group with from 1 to 12 carbon atoms. 
     
     
         5 . The composition of  claim 1 , wherein an extruded film comprising the composition has a replication rate of greater than 75%. 
     
     
         6 . The composition of  claim 1 , wherein an extruded film comprising the composition has a melt flow rate of greater than 50 cm 3 /10 mins as measured according to ASTM D1238-04. 
     
     
         7 . The composition of  claim 1 , wherein an extruded film comprising the composition has a haze of less than 2.2%, as measured according to ASTM D1003-00, Procedure A at 2.54 mm thickness. 
     
     
         8 . The composition of  claim 1 , comprising
 45 to 80 wt % of the polycarbonate;   19 to 55 wt % of the polyester; and   0.01 to 2 total wt % of additives.   
     
     
         9 . A method of manufacturing a textured sheet comprising:
 heating the replication composition of  claim 1  to an extrusion temperature of greater than or equal to a glass transition temperature of the replication composition;   extruding the replication composition through a die to form a sheet;   imprinting a surface texture from a transfer surface onto the sheet; and   cooling the sheet below a glass transition temperature of the replication composition to form a textured sheet.   
     
     
         10 . The method of  claim 9 , further comprising forming a layer of a second composition in direct contact with the replication composition, wherein the second composition comprises the composition of any one or more of  claims 1  to  8 , or a polyarylate, a polystyrene, a polyester, or a combination comprising at least one of the foregoing. 
     
     
         11 . The method of  claim 9 , wherein imprinting occurs before the replication composition is cooled below a glass transition temperature of the replication composition. 
     
     
         12 . The method of  claim 9 , wherein imprinting comprises pressing the sheet between two or more surfaces at a transfer pressure, wherein one of the surfaces comprises the transfer surface. 
     
     
         13 . The method of  claim 9 , wherein imprinting comprises pressing the sheet between two or more rollers at a transfer pressure, wherein a roller comprises the transfer surface disposed along a roller surface. 
     
     
         14 . The method of  claim 9 , wherein cooling occurs within 0.01 to 5 minutes of imprinting; and wherein the cooling is at a rate of 5 to 300° C./minute. 
     
     
         15 . A textured sheet made by the method of  claim 9 . 
     
     
         16 . The textured sheet of  claim 15 , wherein a side of the extruded sheet comprises a surface texture comprising a plurality of micro-structured units. 
     
     
         17 . The textured sheet of  claim 15 , further comprising a second composition in direct contact with a side of the extruded sheet, wherein the second composition comprises the composition of  claim 1  or a polycarbonate, a polyarylate, a polystyrene, a polyester, or a combination of at least one of the foregoing. 
     
     
         18 . The textured sheet of  claim 15 , further comprising a second composition in direct contact with a side of the extruded sheet, wherein the second composition is different than the composition of the extruded sheet. 
     
     
         19 . An article comprising the textured sheet of  claim 15 . 
     
     
         20 . The article of  claim 19 , wherein the article is a light module, an LED light cover, or a diffuser/collimating sheet in a back light module in a display application.